Project Requirements
Keep current generation look and feel
Comply with UL2743, Right to repair, and other new requirements
Portability and Durability
Expandable Capacity
Backwards compatible
Tight Project Timeline (6 months)
Concepting
Design concepts emphasized portability, mobility, and easy capacity expansion. Despite its weight, the Pro 2000 was engineered to be Goal Zero's most rugged, portable, and capable power station to date. This had to be accomplished in approximately half the typical product cycle time.
Form Exploration
It was crucial to maintain the product's generational "feel" while exploring innovative manufacturing and portability solutions. Although the final design ended up adhering more closely to the product family, this exploration provided valuable insights on achieving our goals.
Design Details
From our experience with the current product line, we identified several pain points - particularly the quick and compact connection of expansion batteries to the main unit. We also carefully considered the implementation of telescoping handles, wheels, and a stand. Numerous design iterations were created in CAD before receiving a prototype from our international manufacturers.
Prototypes
Using a combination of internal Rapid Prototyping and Final Prototypes from our international vendors, I could significantly reduce long turn around times. These helped us address assembly, user interaction, and finish issues. After a thorough review by myself and our mechanical engineer, I coordinated with our testing/QA team for comprehensive evaluation. We used their valuable feedback to make improvements.
